High efficiency salient pole machine and method of forming the same

ABSTRACT

A salient pole machine and method of forming the same comprising a rotating field assembly and at least one inter-pole cap connected to the rotating field assembly and/or at least end coil cap connected to the rotating field assembly. Each inter-pole cap preferably includes a top surface that has a curvature and/or at least one cavity. Each end coil cap may include at least one support. The salient pole machine may also include at least one fan assembly independent of the rotating field assembly. In a preferred embodiment, the salient pole machine includes at least one mounting plate, wherein each fan assembly is mounted on the mounting plate. The inter-pole caps and the end coil caps preferably comprise composites, polymers, alloys, ceramics, or naturally occurring materials.

CROSS REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO APPENDIX

Not applicable.

FIELD OF THE INVENTION

The invention relates to salient pole machines, including generators andmotors.

BACKGROUND OF THE INVENTION

In the prior art, the initial cost of salient pole machines such asgenerators and motors was the major factor in purchasing an electricsalient pole machine of a given kW, along with the design and enclosurefrom among suppliers known to provide adequate reliability andavailability. Salient pole machines were normally purchased at thelowest costs and, in most cases, operating losses were largely ignored.

However, the price of crude oil continues to escalate and the operatingcosts of these devices are now a significant factor in the selection ofsalient pole machines. The operating cost associated with generatingelectric energy from salient pole machines cannot be ignored.Furthermore, the reduction in green house gases associated with moreefficient generation of electricity is also desired.

Prime power applications are one area in which high efficiencygenerators units benefit from the teachings of this invention. Thebenefit from this increased efficiency versus the increased cost of theunit can be relatively short and very attractive economically.Therefore, a need exists to increase the efficiency of salient polemachines.

Windage losses are losses associated with the cooling fans and thesalient pole design of the salient pole machine field. In someapplications, windage losses can be the largest individual losscomponent present in the unit. This is due to the need for large amountsof air flow required to avoid excessive temperature rises. Additionally,there are high pressure drops induced by unfavorable geometry. Both ofthese phenomena have lead to very poor fan efficiency in the prior art,which results in large amounts of losses. Therefore, a need exists toreduce windage losses, and therefore improve the efficiency of salientpole machines.

BRIEF SUMMARY OF THE INVENTION

High efficiency salient pole machine such as generators should beselected when the savings in fuel usage is desirable. However, highefficiency salient pole machines provide benefits over and above thefuel savings. The lower loss machines produce less heat and therefore,run at much cooler temperatures than less efficient models. These lowertemperatures result in substantially longer salient pole machine lifesince the life of insulating materials decrease as temperature rises.

To reduce the losses associated with the shaft mounted cooling fans, anew concept of small induction motor driven fans was used to cool theunit. To minimize the salient pole turbulent losses, compositeinter-pole caps and composite end coil caps were used to lessen drag. Inaddition, fan assemblies may be independent of the rotating fieldassembly.

A salient pole machine comprising a rotating field assembly and at leastone inter-pole cap connected to the rotating field assembly and/or atleast one end coil cap connected to the rotating field assembly. Eachinter-pole cap preferably includes a top surface that has a curvatureand/or at least one cavity. The end coil cap may include at least onesupport. The salient pole machine may also include at least one fanassembly independent of the rotating field assembly. In a preferredembodiment, the salient pole machine includes at least one mountingplate, wherein each fan assembly is mounted on the mounting plate. Theinter-pole caps and the end coil caps preferably comprise composites,polymers, alloys, ceramics, or naturally occurring materials.

A method of forming a salient pole machine having a rotating fieldassembly, the method which comprises the step of connecting at least oneinter-pole cap to the rotating field assembly. The method may alsoinclude connecting at least end coil cap to the rotating field assemblyand/or connecting at least one fan assembly independent of the rotatingfield assembly to the salient pole machine. In a preferred embodiment,the inter-pole cap comprises a top surface and wherein the top surfaceof each inter-pole cap has curvature.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows a perspective view of the prior art of a rotating fieldassembly;

FIG. 2 shows a partially exploded, perspective view of an embodiment ofa rotating field assembly;

FIG. 3 shows an assembled, perspective view of an embodiment of arotating field assembly;

FIG. 4 shows an perspective view of an embodiment of a inter-pole cap;

FIG. 5 shows a perspective view of an embodiment of an outboard side ofan end coil cap;

FIG. 6 shows an exploded, perspective view of an embodiment of at leastone fan assembly;

FIG. 7 shows a perspective view of an embodiment of the fan assemblies;and

FIG. 8 shows a perspective view of an embodiment of an assembled salientpole machine.

While the inventions disclosed herein are susceptible to variousmodifications and alternative forms, only a few specific embodimentshave been shown by way of example in the drawings and are described indetail below. The figures and detailed descriptions of these specificembodiments are not intended to limit the breadth or scope of theinventive concepts or the appended claims in any manner. Rather, thefigures and detailed written descriptions are provided to illustrate theinventive concepts to a person of ordinary skill in the art and toenable such person to make and use the inventive concepts.

DETAILED DESCRIPTION

One or more illustrative embodiments incorporating the inventiondisclosed herein are presented below. Not all features of an actualimplementation are described or shown in this application for the sakeof clarity. It is understood that in the development of an actualembodiment incorporating the present invention, numerousimplementation-specific decisions must be made to achieve thedeveloper's goals, such as compliance with system-related,business-related, government-related and other constraints, which varyby implementation and from time to time. While a developer's effortsmight be complex and time-consuming, such efforts would be,nevertheless, a routine undertaking for those of ordinary skill in theart having benefit of this disclosure.

The salient pole machine, a generator, of the prior art lost efficiencyin several areas. FIG. 1 shows a rotating field assembly 100 of agenerator. The rotating field assembly 100 includes rotor poles 102,windings 104, and coil support bars 106. The windings 104 are held inplace by winding supports 108. The open nature of the area between therotor poles 102, wherein the winding supports 108 are located, tends tobe an area where windage losses occur.

A fan assembly 112 is mounted a shaft 110. The prior art has incurredsignificant windage losses because the fan assembly 112 requires largeamounts of mechanical energy. The mechanical energy required to move theair for cooling makes up a large amount of the losses in the efficiencyof the system.

The portion 114 of the windings 104 that extends past the rotor poles102 is another source of windage losses. As the rotating field assembly100 rotates, the portion 114 of the windings 104 and coil support bars106 induce drag that contributes significantly to losses in efficiency.

Those skilled in the art will recognize that a preferred embodiment of asalient pole machine, namely a generator, is described herein. However,all salient pole machines may benefit from the teachings of thisdisclosure and are considered to be within the scope of the invention asdescribed and claimed herein. Salient pole machines are considered toinclude generators and motors.

FIG. 2 is an embodiment of a rotating field assembly 200. The open airarea between rotor poles 202 and the winding supports 208 has beenclosed by inter-pole caps 216. The coil support bars 206 and the portionof windings 214 extending past the rotor poles 202 have been covered byend coil caps 218. There is no fan assembly attached to the shaft 210 inthis embodiment.

FIG. 3 shows an assembled, perspective view of an embodiment of arotating field assembly 300. As shown, the open air areas between rotorpoles 302 have been closed by inter-pole caps 316. The portion ofwindings 314 extending past the rotor poles 302 have been covered by endcoil caps 318. There is no fan assembly attached to the shaft 310 inthis embodiment.

FIG. 4 shows a perspective view of an embodiment of an inter-pole cap416. The inter-pole cap 416 is designed to interface between adjacentrotor poles. In a preferred embodiment, the top surface 420 ofinter-pole cap 416 may have curvature such that when assembled, thecomplete rotating field assembly may approach a cylindrical surface thatis advantageous in reducing windage losses. In a preferred embodiment,at least one cavity 422 may be formed in the inter-pole cap 416 to bothreduce cost of materials used and reduce the total mass of theinter-pole cap 416.

The inter-pole cap 416 may be formed of any material with suitablestructural properties to withstand the forces associated with therotation during operation. This may include, but is not limited tometals, composites, polymers, alloys, ceramics, naturally occurringmaterials, and similar materials. In preferred embodiment, glassreinforced epoxy composites are preferable for electrical, mass, andstrength properties. In a most preferred embodiment, the inter-pole cap416 may be formed from G-11 glass reinforced epoxy composite, howeverthose skilled in the art will recognize that significant variation inmaterials are considered to be within the scope of the invention.

FIG. 5 shows perspective views of an embodiment of an end coil cap 518.The outer diameter 524 of the end coil cap 518 is preferably similar orthe same as the outer diameter of the rotating field assembly. Thepurpose of making this diameter substantially equal is to reduce windagelosses from an uneven interface between surfaces. The depth of the endcoil cap 518 is such that the full enclosure of the windings and thecoil support bars is achieved. Adequate internal clearance of thewindings is preferable. The mounting surface 526 on the end coil cap 518is such that it may interface with the coil support bars. In a preferredembodiment, the end coil cap 518 is bolted to the coil support bars inan axial direction. The end coil cap 518 may also include structuralsupports 528 that offer additional rigidity while being formed in amanner that does not interfere with the internal components of therotating field assembly.

The end coil cap may also be formed of any material with suitablestructural properties to withstand the forces associated with therotation during operation. This may include, but is not limited tometals, composites, polymers, alloys, ceramics, naturally occurringmaterials, and similar materials. In preferred embodiment, glassreinforced epoxy composites are preferable for electrical, mass, andstrength properties. In a most preferred embodiment, the inter-pole cap518, 618 may be formed from G-11 glass reinforced epoxy composite,however those skilled in the art will recognize that significantvariation in materials are considered to be within the scope of theinvention.

FIG. 6 shows an exploded, perspective view of an embodiment of at leastone fan assembly independent of the rotating field assembly. As shown, aplurality of fan assemblies 630 interface with a mounting plate 632.Screens 634 may be disposed on the mounting plate 632 on the outboardside of the fan assemblies 630. In a preferred embodiment, an accesscover 636 may also be disposed on the mounting plate 632. Thisarrangement provides a lower load alternative to a shaft mounted fan.

FIG. 7 shows a perspective view of an embodiment of the fan assemblies730. The fan assemblies 730 interface with the mounting plate 732. Thesefan assemblies 730 are preferably bolted to the mounting plate 732.Screens 734 may be disposed on the mounting plate 732 on the outboardside of the fan assemblies 730. These screens 734 are preferably boltedto the mounting plate 732.

In this embodiment, four fan assemblies are shown; however those skilledin the art will recognize that any number of fan assemblies capable ofproviding airflow over the internal components of the salient polemachine is considered to be within the scope of the invention. Thoughsignificant variation in the amount of airflow needed is expected basedon the need of the salient pole machine, the most preferred embodimentis capable of generating at least about 2000 CFM of airflow. This variesbased on frame size, stack length, type of fan used, operatingenvironments, and similar variables. The mounting plate is preferablymade of steel or similarly rigid material capable of structurallysupporting each fan assembly during operation. Those skilled in the artwill recognize that significant variation of the material for themounting plate is considered to be within the scope of the invention.

FIG. 8 shows a perspective view of an embodiment of an assembled salientpole machine 800. The salient pole machine 800 shows the fan assemblyhousing 836 connected to the armature assembly 838. The rotor 840, alsoreferred to herein as the rotating field assembly, can be seen internalof the armature assembly 838.

The invention has been described in the context of preferred and otherembodiments and not every embodiment of the invention has beendescribed. Obvious modifications and alterations to the describedembodiments are available to those of ordinary skill in the art. Thedisclosed and undisclosed embodiments are not intended to limit orrestrict the scope or applicability of the invention conceived of by theApplicants, but rather, in conformity with the patent laws, Applicantsintends to protect all such modifications and improvements to the fullextent that such falls within the scope or range of equivalent of thefollowing claims.

1. A salient pole machine comprising: a rotating field assembly; and atleast one inter-pole cap connected to the rotating field assembly. 2.The salient pole machine of claim 1, wherein each inter-pole capcomprises a top surface and wherein the top surface of each inter-polecap has a curvature.
 3. The salient pole machine of claim 1, whereineach inter-pole cap comprises at least one cavity.
 4. The salient polemachine of claim 1, wherein each inter-pole cap comprises composites,polymers, alloys, ceramics, or naturally occurring materials.
 5. Thesalient pole machine of claim 1, further comprising at least one endcoil cap connected to the rotating field assembly.
 6. The salient polemachine of claim 5, wherein each end coil cap comprises composites,polymers, alloys, ceramics, or naturally occurring materials.
 7. Thesalient pole machine of claim 1, further comprising at least one fanassembly independent of the rotating field assembly.
 8. The salient polemachine of claim 7, further comprising at least one mounting plate,wherein each fan assembly is mounted on the mounting plate. 9.(canceled)
 10. (canceled)
 11. (canceled)
 12. (canceled)
 13. (canceled)14. (canceled)
 15. (canceled)
 16. (canceled)
 17. A method of forming asalient pole machine having a rotating field assembly, the method whichcomprises the step of connecting at least one inter-pole cap to therotating field assembly.
 18. The method of claim 17, which furthercomprises the step of connecting at least end coil cap to the rotatingfield assembly.
 19. The method of claim 17, which further comprises thestep of connecting at least one fan assembly independent of the rotatingfield assembly to the salient pole machine.
 20. The method of claim 17,wherein each inter-pole cap comprises a top surface and wherein the topsurface of each inter-pole cap has curvature.